Sanding system

ABSTRACT

A sanding system comprising a flexible base, a flexible sanding element, and a dust suction device is disclosed. The flexible base has an upper surface and a lower surface. The flexible sanding element is attached to the flexible base so as to form a closed air-tight joint. The flexible sanding element has an upper surface, a lower sanding surface, and at least one aperture extends through the flexible sanding element. A space is defined between the lower surface of the flexible base and the upper surface of the flexible sanding element. The space is in fluid communication with the aperture, and a dust suction device is in fluid communication with the space.

FIELD OF THE INVENTION

The present invention generally relates to surface finishing tools and, more specifically, to a sanding system.

BACKGROUND OF THE INVENTION

In hand sanding, the user holds a sanding sponge or a sand paper directly in his or her hand to move the sanding sponge or the sand paper on the work surface. Sanding by hand can, of course, be an arduous task. To facilitate the hand sanding process, the sanding sponge or the sand paper may be placed in a holder. Holders can be readily grasped by the user to make hand sanding faster and easier. The holders for the sanding sponges are disclosed in the patented prior art. U.S. Pat. No. 6,378,237 (Gordon), for example, discloses a holder for releasably retaining an abrasive sponge. The holder comprises a base for holding the sponge therein, the base having a top surface and the surface depending downwardly from the top surface to border the sponge partially along at least three of its sides, and a handle being releasably connected to the top surface of the base.

When sanding surfaces are sanded, small particles of dust are released into the air and surrounding surfaces. These particles often settle over the sanded surface. To clean the surface, the user must use a separate cleaning tool, such as a dusting cloth or tack cloth, to clean the surface. It may be time consuming to locate and use a separate tool.

In order to collect dust generated during sanding, sanding tools that can be connected with a vacuum device have been developed. U.S. Patent Publication No. 2006/0199484 (Brown), for example, discloses a resilient sanding block of the type comprising a core having a plurality of exterior surfaces, including a first major surface, a second major surface and side surfaces, and having a layer of abrasive material disposed thereon. The resilient sanding block may have one or more apertures or through holes extending from one major surface to the other major surface and channels formed in at least one of the major surfaces, and the channels being in communication with the aperture. When a vacuum source is operatively connected to the aperture, the dust created by sanding will be substantially sucked into the vacuum source via the channels and the aperture. A holder for a resilient sanding block and a handle for the holder are also disclosed, which forms a sanding system together with the sanding block.

However, the holders are usually made by rigid material and may prevent the sanding tool from sanding an adjacent edge or a curling surface. Moreover, although the vacuum source is developed to be used with the sanding tool, this kind of sanding tool may be difficult to be manufactured by the manufacturer and carried by the user.

There is a need for a flexible sanding tool which is able to conform to irregular surfaces, especially curved surfaces. There is a need for a portable sanding tool which can be easily carried and transported by the user. There is a need for a sanding tool which is low cost to manufacture. There is a need for a compact and light-weight sanding tool.

SUMMARY OF THE INVENTION

In light of the problems and deficiencies inherent in the prior art, the present invention seeks to overcome these by providing a sanding system having a flexible sanding block that can be used to control or remove the dust on curved surfaces while sanding.

According to one aspect of the present invention, the sanding system comprises a sanding block which has a flexible base and a flexible sanding element and a dust suction device. The flexible base has an upper surface and a lower surface, The flexible sanding element having an upper surface and a lower sanding surface is attached to the flexible base by a circumferential seal. At least one aperture, as passage for dust or debris, extends through the flexible sanding element. A space is defined between the lower surface of the flexible base and the upper surface of the flexible sanding element and is in fluid communication with the aforementioned aperture. A dust suction device that can generate a suction force is attached to the sanding block. Using this system, dust or debris on a surface can be sucked into the space via the aperture, then into the dust suction device.

The sanding system further comprises a rotatable coupler that connects the sanding block to the dust suction device. By the coupler, the dust suction device is in fluid communication with the space.

In one embodiment, the sanding system further comprises a carrier for fastening the dust suction device to the user such that the sanding system is portable so as to be convenient for the user. Generally speaking, the carrier comprises a main body for carrying the dust suction device thereon and a fastening means for fastening the main body to the user. For example, the carrier can be a shoulder bag.

In another embodiment, the sanding system further comprises a flexible hand holder attached on the upper surface of the flexible base.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that advantages and objects of the invention are obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof that are illustrated in the appended drawings. These drawings depict only typical embodiments of the invention. They are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIG. 1 illustrates a perspective view of a sanding system according to one embodiment of the present invention;

FIG. 2 illustrates a perspective view of the bottom of a sanding block of the sanding system in FIG. 1;

FIG. 3 illustrates a perspective view of the top of the sanding block of the sanding system in FIG. 1;

FIG. 4 illustrates an enlarged view of FIG. 2 with a sanding element of the sanding block partially cut away;

FIG. 5 illustrates a perspective view of the coupler of FIG. 2;

FIG. 6 illustrates a schematic sectional view of a dust suction device with the compressed air source removed according to one embodiment of the present invention.

DESCRIPTION

The following detailed description of exemplary embodiments of the invention makes reference to the accompanying drawings, which show, by way of illustration, exemplary embodiments in which the invention may be practiced. While these exemplary embodiments are described in sufficient detail to enable those skilled in the art practice the invention, it should be understood that other embodiments may be realized and that various changes to the invention may be made without departing from the spirit and scope of the present invention. Thus, the following more detailed description of the embodiments of the present invention, as represented in the figures, is not intended to limit the scope of the invention as claimed. It is presented for purposes of illustration only and to describe the features and characteristics of the present invention, to set forth the best mode of operation of the invention, and to sufficiently enable one skilled in the art to practice the invention. Accordingly, the scope of the present invention is to be defined solely by the appended claims.

The following detailed description and exemplary embodiments of the invention will be best understood by reference to the accompanying drawings, wherein the elements and features of the invention are designated by numerals throughout.

FIG. 1 shows one embodiment of the present invention. Generally, the sanding system 100 comprises a sanding block 200 and a dust suction device 300. More specifically, the sanding block 200 is best shown in FIGS. 2-5 and an example of the dust suction device 300 is schematically shown in FIG. 6.

The sanding block 200 is generally round, and comprises a base 202 having an upper surface 202 a and a lower surface 202 b, a sanding element 204 having an upper surface 204 a, a lower surface 204 b as a sanding surface, and a plurality of apertures 204 c passing through the upper surface 204 a and the lower surface 204 b, and a coupler 206. The coupler 206 is rotatably positioned within a through hole 202 d in the base 202 at one end 206 a thereof, and the other end 206 b thereof is connected to an inlet of the dust suction device 300. As shown in FIG. 3, a hand holder 208 is a resilient band attached to the base 202 by sewing or thermal bonding, and can be used to attach the sanding block 200 to a hand and allow the user to move the sanding block 200 easily after the user placed his/her hand under the hand holder 208 with the palm downward. The base 202, the sanding element 204, the coupler 206 and the hand holder 208 can be made of flexible material, preferably neoprene rubber. However, it will be understood that other materials having similar properties may be used without departing from the sprite and scope of the present invention. In the illustrated embodiment, the sanding element 204 is a flexible pad with the lower surface for adhering the abrasive articles or abrasive particles. In another embodiment, the sanding element can be constituted by a pad and an attachable sand paper layer, wherein the pad has at least one aperture, and at the same time the sand paper layer has at least one aperture corresponding to the aperture in the pad and sticks to the lower surface of the pad. Also, it will be understood that the sanding element can be a sand paper. In order to prevent air from escaping through the joint between the base 202 and the sanding element 204, the sanding element 204 is attached to the base 202 by circumferential sealing preferably by the manners such as sewing, thermal bonding and etc, and so the formed joint is a closed and substantial air-tight seam. Indeed, the ordinary person skilled in the art will understand that other connection methods also can be selected and applied between the base 202 and the sanding element 204 depending on the material thereof, and accordingly the present invention is not limited to the above methods but other suitable connection methods will be also deemed as falling within the scope of the present invention. By attached the sanding element 204 to the base 202, a space is defined by the lower surface 202 b of the base 202 and the upper surface 204 a of the sanding element 204. Moreover, the space is in fluid communication with the apertures 204 c in the sanding element 204 and the coupler 206.

Advantageously, the lower surface 202 b of the base 202 has a plurality of generally rectangular projections 202 c spaced uniformly and aligned in several lines. These projections 202 c partially occupy the space and form channels between them. As shown in FIG. 4, the height of these projections 202 c is lower than the distance from the lower surface 202 b of the base 202 to the upper surface 204 a of the sanding element 204. More particularly, the apertures 204 c in the sanding element 204 are aligned with the channels between these projections 202 c so as to achieve a better suction effect. Additionally, these projections 202 c can provide support for the upper surface 204 a of the sanding element 204 during in use.

Alternatively, these projections 202 c can be substituted by at least one recess formed in the lower surface 202 b of the base 202, and at the same time the recess could be configured to align with the apertures 204 c in the sanding element 204 for a better suction effect.

Although it is recited above that the projections 202 c are formed on the lower surface 202 b of the base 202, the person skilled in the art will readily know that these projections 202 c also can be formed on the upper surface 204 a of the sanding element 204. Additionally, these projections 202 c can be integrally formed with the base 202 or the sanding element 204 by molding, cutting or other means. Moreover, the projections 202 c can be in any other shape and also can be aligned in a circle. Accordingly, the present invention should not be limited to the configuration of these projections (or channels) but could include any projections (or channels) configuration or pattern that serves the purpose of a passage for sucking dust or debris.

Referring to FIG. 1 and FIG. 6, the dust suction device 300 comprises a compressed air source (not illustrated) for generating compressed air, a chamber 300 a having an inlet connected to the end 206 b of the coupler 206 and an outlet communicated to ambient air, and a tube 300 b having an inlet connected to the compressed air source and an outlet connected to the chamber 300 a.

When the dust suction device 300 as shown in FIG. 6 is connected to the end 206 b of the coupler 206, the apertures 204 c in the sanding element 204, the channels within the sanding block 200, and the chamber 300 a are in fluid communication. Therefore, when the user holds the sanding block 200 and wipes a dirty surface with the lower sanding surface 204 b of the sanding element 204, the compressed air is released outward from the outlet of the chamber 300 a via the tube 300 b and the chamber 300 a, and the dust or debris created by the lower sanding surface 204 b is released into the ambient air via the apertures 204 c, the channels, the coupler 206 and the chamber 300 a under the suction force generated by the compressed air.

In another embodiment, the dust suction device 300 can comprise a dust collecting element for collecting the dust or debris and a vacuum source for generating a vacuum environment in the dust collecting element, wherein the vacuum source is coupled to the dust collecting element by one of some known methods in the prior art such that a negative pressure occurs within the dust collecting element. More particularly, the dust collecting element is a filter bag that can store the sanded dust or debris.

When the dust collecting element is connected to the end 206 b of the coupler 206, the apertures 204 c in the sanding element 204, the channels within the sanding block 200, and the dust collecting element are in fluid communication. Therefore, when the user holds the sanding block 200 and wipes a dirty surface with the lower sanding surface 204 b of the sanding element 204, the dust or debris created by the lower sanding surface 204 b is sucked and collected into the dust collecting element via the apertures 204 c, the channels, the coupler 206 under the suction force generated by the vacuum source.

Suitable dust collecting elements are disclosed in the following patent publications: US 2009/0056548 entitled Dust Collecting Device For A Sanding Tool; US 2010/0285728 entitled Dust Collecting Device For A Sanding Tool; and US 2011/0239599 entitled Dust Collecting Device For A Sanding Tool, all of which are incorporated into the present application by reference.

For the purpose of using easily, in one embodiment, the sanding system 100 further comprises a carrier for fastening to the user. Typically, the carrier can comprise a main body for carrying the dust suction device 300 thereon and a binding or fastening means for fastening the main body to the user. In particularly, the carrier can be a shoulder bag. Another suitable carrier is disclosed in the patent publication US 2012/0061438 entitled Backpack For Filter Bag Used In Conjunction With A Pneumatic Sander.

The foregoing detailed description describes the invention with reference to specific exemplary embodiments. However, it will be appreciated that various modifications and changes can be made without departing from the scope of the present invention as set forth in the appended claims. The detailed description and accompanying drawings are to be regarded as merely illustrative, rather than as restrictive, and all such modifications or changes, if any, are intended to fall within the scope of the present invention as described and set forth herein.

More specifically, while illustrative exemplary embodiments of the invention have been described herein, the present invention is not limited to these embodiments, but includes any and all embodiments having modifications, omissions, combinations (e.g., of aspects across various embodiments), adaptations and/or alterations as would be appreciated by those in the art based on the foregoing detailed description. The limitations in the claims are to be interpreted broadly based on the language employed in the claims and not limited to examples described in the foregoing detailed description or during the prosecution of the application, which examples are to be construed as non-exclusive. For example, in the present disclosure, the term “preferably” is non-exclusive where it is intended to mean “preferably, but not limited to”. Means-plus-function limitations will only be employed where for a specific claim limitation all of the following conditions are present in that limitation: a) “means for” is expressly recited; b) a corresponding function is expressly recited; and c) structure, material or acts that support that structure are expressly recited. Accordingly, the scope of the invention should be determined solely by the appended claims and their legal equivalents, rather than by the descriptions and examples given above. 

1. A sanding system, comprising: a flexible base having an upper surface and a lower surface; a flexible sanding element attached to the flexible base by circumferential sealing, the flexible sanding element having an upper surface and a lower sanding surface, wherein at least one aperture extends through the flexible sanding element; a space defined between the lower surface of the flexible base and the upper surface of the flexible sanding element, the space being in fluid communication with the at least one aperture; and a dust suction device in fluid communication with the space.
 2. The sanding system according to claim 1, wherein the lower surface of the flexible base has a plurality of projections partially occupying the space and forming a plurality of channels.
 3. The sanding system according to claim 1, wherein the upper surface of the flexible sanding element has a plurality of projections partially occupying the space and forming a plurality of channels.
 4. The sanding system according to claim 1, wherein the sanding system further comprises a coupler by which the dust suction device is in fluid communication with the space.
 5. The sanding system according to claim 4, wherein the coupler is rotatable.
 6. The sanding system according to claim 1, wherein the dust suction device comprises a chamber and a compressed air source in communication with the chamber, wherein the chamber is configured such that dust or debris created by the lower sanding surface is released into ambient air via the aperture, the space and the chamber under suction of compressed air from the compressed air source.
 7. The sanding system according to claim 1, wherein the dust suction device comprises a dust collecting element and a vacuum source; the vacuum source being coupled with the dust collecting element, and the dust collecting element being in fluid communication with the space, such that dust or debris created by the lower sanding surface is sucked into the duct collecting element via the aperture and the space.
 8. The sanding system according to claim 7, wherein the dust collecting element is a filter bag.
 9. The sanding system according to claim 1, wherein the sanding system further comprises a carrier for=fastening the dust suction device to the user.
 10. The sanding system according to claim 9, wherein the carrier comprises a main body for carrying the dust suction device thereon, and a fastening means for fastening the main body to the user.
 11. The sanding system according to claim 10, wherein the carrier is a shoulder bag.
 12. The sanding system according to claim 1, wherein the sanding system further comprises a flexible hand holder attached on the upper surface of the flexible base.
 13. The sanding system according to Claim 12, wherein the flexible hand holder is a resilient band.
 14. The sanding system according to claim 1, wherein the flexible sanding element comprises a coated abrasive article.
 15. The sanding system according to claim 1, wherein the flexible sanding element comprises a sand paper.
 16. The sanding system according to claim 1, wherein the flexible base comprises a resilient pad and a sand paper layer attached to the resilient pad.
 17. A sanding block for using with a dust suction device, comprising: a flexible base having an upper surface and a lower surface; a flexible sanding element attached to the flexible base by circumferential sealing, the flexible sanding element having an upper surface and a lower sanding surface, wherein at least one aperture extends through the flexible sanding element; and a space defined between the lower surface of the flexible base and the upper surface of the flexible sanding element, the space being in fluid communication with the at least one aperture. 